U.S. patent application number 11/359128 was filed with the patent office on 2007-08-23 for system and method for re-synchronizing an access barrier with a barrier operator.
Invention is credited to Willis J. Mullet, Paul J. VanDrunen.
Application Number | 20070194218 11/359128 |
Document ID | / |
Family ID | 37951482 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070194218 |
Kind Code |
A1 |
Mullet; Willis J. ; et
al. |
August 23, 2007 |
System and method for re-synchronizing an access barrier with a
barrier operator
Abstract
A system for re-synchronizing an access barrier with a barrier
operator comprises an access barrier, and a barrier operator to
profile and monitor the manual and automatic movements of the
access barrier. The barrier operator comprises a controller, a
memory, a motor pivot encoder, and a counting encoder. The memory
contains a primary counter to store the distance measured by the
counting encoder, while a secondary counter maintains a value equal
to the travel of the access barrier as determined by a profiling
operation initiated prior to operating the barrier operator. The
controller takes into account the counts of the primary and
secondary counters, along with the stored profile information,
allows the re-synchronization system to determine the proper amount
of movement to be applied to open or close the access barrier, in
the event the access barrier has been manually moved.
Inventors: |
Mullet; Willis J.; (Gulf
Breeze, FL) ; VanDrunen; Paul J.; (Navarre,
FL) |
Correspondence
Address: |
RENNER, KENNER, GREIVE, BOBAK, TAYLOR & WEBER
FIRST NATIONAL TOWER FOURTH FLOOR
106 S. MAIN STREET
AKRON
OH
44308
US
|
Family ID: |
37951482 |
Appl. No.: |
11/359128 |
Filed: |
February 21, 2006 |
Current U.S.
Class: |
250/231.13 |
Current CPC
Class: |
E05Y 2400/342 20130101;
E05Y 2201/244 20130101; E05Y 2900/106 20130101; E05Y 2800/11
20130101; E05F 15/603 20150115; E05F 15/668 20150115 |
Class at
Publication: |
250/231.13 |
International
Class: |
G01D 5/34 20060101
G01D005/34 |
Claims
1. An operator to move an access barrier comprising: a motor drive;
a counterbalance system selectively engageable with said motor
drive, said counterbalance system adapted to move the access
barrier between limit positions when engaged by said motor drive or
when moved manually; an encoder wheel associated with one of said
motor drive and said counterbalance system, said encoder wheel
rotating whenever the access barrier is moved; a counting encoder
associated with said encoder wheel and generating a count signal
when said encoder wheel is rotated; and a controller which receives
said count signal and which maintains a primary count and a
secondary count to determine a position of the access barrier
regardless of whether the access barrier is moved by said motor
drive or manually.
2. The operator according to claim 1, further comprising: a profile
table maintained by said controller which correlates operational
parameters with barrier position, wherein said controller compares
data stored in said profile table with actual data generated by
said counting encoder to determine which of said primary count and
said secondary count to use in determining the position of the
access barrier.
3. The operator according to claim 2, wherein said controller
re-sets said primary count to a value of said secondary count when
real-time operational parameters detected by said controller more
closely approximate operational data in said profile table
associated with a barrier position associated with said secondary
count.
4. The operator according to claim 3, wherein said motor drive is
pivotable with respect to said counterbalance system.
5. The operator according to claim 4, further comprising: a blocker
tab carried by said motor drive and pivoting therewith, said motor
drive pivoting at least when the barrier moves into the closed
position; and a motor pivot encoder associated with said blocker
tab and generating a blocker signal when said motor drive pivots,
said controller deactivating said motor drive when said blocker
signal is received and said primary counter has been decremented to
about a zero value.
6. The operator according to claim 1, wherein movement of the
barrier from the closed limit position toward an open limit
position is detected by said motor pivot encoder and said
controller resets at least said primary count.
7. The operator according to claim 1, wherein movement of the
barrier in one direction is detected by said counting encoder and
said controller increments said primary count and said secondary
count, and wherein movement of the barrier in another direction is
detected by said counting encoder and said controller decrements
said primary count and said secondary count.
8. The operator according to claim 7, wherein said controller
adjusts said primary counter and said secondary counter when said
counterbalance system moves the access barrier.
9. The operator according to claim 8, wherein said controller
adjusts only said primary counter when said counterbalance system
is disengaged from said motor and the access barrier is moved.
10. The operator according to claim 7, wherein said encoder wheel
provides a directional marker detectable by said counting encoder
which generates a directional pulse received by said controller to
determine directional movement of the barrier.
11. A re-synchronization system for an access barrier comprising: a
counterbalance system having a rotatable drive tube that carries an
encoder wheel, said drive tube adapted to move the access barrier
between limit positions; a motor drive selectively coupled to said
counterbalance system, said motor drive adapted to engage said
drive tube; a counting encoder to detect the movement of said
encoder wheel as said access barrier moves between open and closed
positions; and a controller having a memory that maintains a
primary counter, a secondary counter, and a profile table
containing a plurality of profiled data, said controller coupled to
said counting encoder and said motor drive, wherein said primary
counter stores a primary count equal to the measured travel count
less a manual move count if any, and said secondary counter stores
a travel distance count acquired from said profile table; wherein
upon the start of each operator move, said primary count and said
secondary count are decremented in accordance with the movement of
said encoder wheel, said controller collecting sample data from
said counting encoder, whereby after each successive decrement,
said profile data corresponding to each decremented primary count
and said secondary count are each compared to said sampled data,
whereupon if said sampled data match the profiled data
corresponding to said primary count, said operator move continues,
but if said sampled data matches said profile data corresponding to
said secondary count, then said primary counter is loaded with said
secondary count, and the operator move of the access barrier is
completed in accordance with said primary counter.
12. The re-synchronization system of claim 11, further comprising:
a blocker tab carried by said motor drive, said blocker tab
rotating as said access barrier moves between open and closed
positions; and a motor pivot encoder coupled to said controller,
said motor pivot encoder adapted to detect movement of said blocker
tab, wherein if movement of said blocker tab is detected, and said
primary count is equal to zero, then said barrier operator is
deactivated by said controller.
13. The re-synchronization system of claim 11, wherein said
profiled data comprises the current draw of said motor drive.
14. The re-synchronization system of claim 13, wherein said sampled
data comprises the current draw of said motor drive.
15. The re-synchronization system of claim 11, wherein said
profiled data comprises the pulse velocity of said encoder
wheel.
16. The re-synchronization system of claim 15, wherein said sampled
data comprises the pulse velocity of said encoder wheel.
17. A method for re-synchronizing an access barrier with a barrier
operator comprising: providing profile data associated with a
plurality of positions along the travel of said access barrier;
providing a primary counter and a secondary counter, said secondary
counter maintaining a travel distance count; performing a first
operator move, wherein said primary counter maintains a measured
distance count; performing a manual move of said access barrier to
an intermediate position between opened and closed positions,
wherein said measured distance count maintained in said primary
counter is updated to reflect the change in position of said access
barrier; performing a second operator move of said access barrier;
updating said measured distance count maintained in said primary
counter by an incremental value, said incremental value associated
with the relative positional change of said access barrier during
said second operator move of said access barrier; updating said
travel distance count stored in said secondary counter by said
incremental value; generating real-time data associated with a
plurality of positions along the travel of said access barrier; and
comparing said profiled data corresponding to said updated measured
distance count with said real-time data, wherein said method
returns to said first updating step if said profiled data and said
real-time data matches.
18. The method of claim 17, further comprising: comparing said
profiled data corresponding to said updated travel distance count
with said real-time data if no match if made in said first
comparing step, wherein said updated travel distance count value is
stored in said primary counter if said profiled data matches said
real-time data.
19. The method of claim 18, further comprising: reversing the
movement of said access barrier if no match is made at said second
comparing step.
20. The method of claim 17, further comprising: checking whether a
blocker tab has been detected by said barrier operator after first
updating step, if said primary counter maintains a count of
zero.
21. The method of claim 20, further comprising: storing said
updated travel distance count value in said primary counter if said
blocker tab has not been detected by said barrier operator.
22. The method of claim 17, further comprising: exiting said method
if after said second updating step said secondary counter maintains
a count of zero.
Description
TECHNICAL FIELD
[0001] Generally, the present invention relates to motorized
barrier operators that move access barriers between limit
positions. Specifically, the present invention relates to a system
for re-synchronizing an access barrier with a barrier operator so
that a position of the access barrier between open and closed
positions is always known. Particularly, the present invention
relates to a system and method of re-synchronizing an access
barrier with a barrier operator, such that normal operation of the
barrier operator can resume after the access barrier has been
manually repositioned.
BACKGROUND
[0002] Typical barrier operators use a variety of systems to
monitor the relative location of an access barrier as it moves
between open and closed positions. In addition, should a user
disengage the access barrier from the barrier operator, and
manually move it upward or downward, the barrier operator must be
capable of compensating for such movement by determining the amount
of travel needed to fully open or close the access barrier when it
is reactivated. However, many barrier operators have difficulty
relocating the position of the access barrier, or otherwise
re-synchronizing the access barrier with the barrier operator when
the access barrier is manually disconnected from the operator,
moved to another position and then reconnected.
[0003] In light of this problem, numerous systems have been
developed. In one system, a potentiometer is connected to a drive
tube of a counter-balance system of the barrier operator. During
the opening or closing of the access barrier, the drive tube
rotates causing the voltage potential of the potentiometer to
change in relation to the position of the access barrier. However,
such systems are susceptible to environmental fluctuations such as
temperature change and physical wear, which leads eventually to
inaccurate identification of access barrier position. Other systems
utilize a pulse counting encoder, and an encoder wheel that is
associated with the drive tube of the barrier operator. When the
motorized operator moves the barrier, the encoder wheel rotates as
the access barrier moves between open and closed positions and this
rotation is detected by the pulse counting encoder. Unfortunately,
if the access barrier is moved independently of the encoder wheel,
such as when the access barrier is disconnected from the operator
and manually moved, the positional data that identifies the
relative position of the access barrier may be lost, or
inaccurately characterized.
[0004] While great effort has been made to overcome some of the
obstacles presented in the art, impediments to a complete success
are still present. For example, in the case of the barrier operator
utilizing a pulse counting encoder and encoder wheel, the initial
motorized movement of the access barrier is to find a stalled
condition for the purpose of resetting the encoder count. But this
requires the barrier to be moved to both the open or closed
position and the motor to stall out against a "hard stop." A "hard
stop" occurs when the barrier is moved to its extreme physical
limits. Such activity is damaging to the operator and barrier
components, resulting in premature component failures.
[0005] Another attempt to overcome the obstacles presented in the
art is referred to as a passpoint system as described in U.S. Pat.
No. 6,895,355. In such a system, the barrier operator employs a
passpoint event generator that generates a unique passpoint event
as the access barrier moves between open and closed positions. When
a predetermined passpoint event is detected, an incremental
movement sensor is recalibrated. However, the implementation of
such a passpoint system into a barrier operator may be at
substantial expense, which may hamper widespread adoption of such
systems.
[0006] Therefore, there is a need for a re-synchronization system
for a barrier operator that allows the position of the access
barrier to be identified after the access barrier has been manually
disengaged from the barrier operator, moved, and reattached to the
barrier operator. And there is a need for re-synchronization of the
access barrier to the operator without requiring an undesirable
hard stop. Still yet there is a need for a re-synchronization
system for a barrier operator that is of a low cost and reliable in
operation.
SUMMARY OF THE INVENTION
[0007] In light of the foregoing, it is a first aspect of the
present invention to provide a system and method for
re-synchronizing an access barrier with a barrier operator.
[0008] It is another aspect of the present invention to provide an
operator to move an access barrier comprising a motor drive, a
counterbalance system selectively engageable with the motor drive,
the counterbalance system adapted to move the access barrier
between limit positions when engaged by the motor drive or when
moved manually, an encoder wheel associated with one of the motor
drive and the counterbalance system, the encoder wheel rotating
whenever the access barrier is moved, a counting encoder associated
with the encoder wheel and generating a count signal when the
encoder wheel is rotated, and a controller which receives the count
signal and which maintains a primary count and a secondary count to
determine a position of the access barrier regardless of whether
the access barrier is moved by the motor drive or manually.
[0009] Yet another aspect of the present invention is to provide a
re-synchronization system for an access barrier comprising a
counterbalance system having a rotatable drive tube that carries an
encoder wheel, the drive tube adapted to move the access barrier
between limit positions, a motor drive selectively coupled to the
counterbalance system, the motor drive adapted to engage the drive
tube, a counting encoder to detect the movement of the encoder
wheel as the access barrier moves between open and closed
positions, and a controller having a memory that maintains a
primary counter, a secondary counter, and a profile table
containing a plurality of profiled data, the controller coupled to
the counting encoder and the motor drive, wherein the primary
counter stores a primary count equal to the measured travel count
less a manual move count if any, and the secondary counter stores a
travel distance count acquired from the profile table, wherein upon
the start of each operator move, the primary count and the
secondary count are decremented in accordance with the movement of
the encoder wheel, the controller collecting sample data from the
counting encoder, whereby after each successive decrement, the
profile data corresponding to each decremented primary count and
the secondary count are each compared to the sampled data,
whereupon if the sampled data match the profiled data corresponding
to the primary count, the operator move continues, but if the
sampled data matches the profile data corresponding to the
secondary count, then the primary counter is loaded with the
secondary count, and the operator move of the access barrier is
completed in accordance with the primary counter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] This and other features and advantages of the present
invention will become better understood with regard to the
following description, appended claims, and accompanying drawings
wherein:
[0011] FIG. 1 is a rear perspective view of a sectional overhead
garage door installation showing a barrier operator
re-synchronization system according to the concepts of the present
invention installed in operative relation thereto, with the barrier
operator depicted in an operating position;
[0012] FIG. 2 is a top perspective view of the barrier operator
containing a barrier re-synchronization system according to the
present invention, to show the relationship between an encoder
wheel and a blocker tab;
[0013] FIG. 2A is an exploded perspective view of the barrier
operator shown in FIG. 2;
[0014] FIG. 3 is a block diagram of the barrier operator including
the barrier re-synchronization system according to the present
invention;
[0015] FIG. 4 is a perspective view showing the underside of the
barrier operator;
[0016] FIG. 4A is an enlarged view of a counting encoder and a
motor pivot encoder of the re-synchronization system;
[0017] FIG. 5 is a perspective view of the topside of the barrier
operator showing an embodiment of the re-synchronization system
having an encoder wheel mounted to a shaft extending from a motor
drive;
[0018] FIGS. 6A-C show the barrier operator in a side elevational
view further illustrating the motor pivot encoder, wherein FIG. 5A
shows an obstructed position, FIG. 5B shows a barrier locked
position, and FIG. 5C shows an operational position; and
[0019] FIGS. 7A and 7B show a flow chart showing the operational
steps taken by the re-synchronization system when the access
barrier has been manually disengaged, and repositioned.
BEST MODE FOR CARRYING OUT THE INVENTION
[0020] A re-synchronization system according to the concepts of the
present invention, is generally referred to by the numeral 10 as
shown in the FIGS. 1-5. The re-synchronization system 10 is part of
a barrier operator 12, which is shown in FIG. 1 mounted in
conjunction with an access barrier 14, such as a sectional door.
While the access barrier 14 may comprise a sectional garage door
commonly utilized in garages for residential housing, the barrier
operator 12 and associated re-synchronization system 10 may be
employed with other barriers such as curtains, awnings, gates, and
the like. Moreover, the re-synchronization system 10 may be used
with pivoting-type barrier operators such as the barrier operator
12 discussed herein, but should not be limited thereto, as the
re-synchronization system 10 may be easily modified to be used in
association with trolley-type barrier operators or jack shaft-type
barrier operators to name just a few.
[0021] The opening in which the access barrier 14 is positioned for
opening and closing movements relative thereto is defined by a
frame 20, which is comprised of a pair of spaced jambs 22,24, which
are generally parallel and extend vertically upwardly from the
floor (not shown). The jambs 22,24 are spaced apart and joined at
their vertical upper extremity by a header 26 to thereby delineate
a generally inverted u-shaped frame around the opening of the
access barrier 14. The jambs 22,24 and header 26 are normally
constructed of lumber, as is well known to persons skilled in the
art, for purposes of reinforcement and facilitation the attachment
of elements supporting and controlling the access barrier 14,
including the barrier operator 12, and the re-synchronization
system 10.
[0022] Affixed to the jambs 22,24 proximate the upper extremities
thereof and the lateral extremities of the header 26 to either side
of the access barrier 14 which are secured to the underlying jambs
22,24 respectively. Connected to and extending from flag angles 28,
are respective tracks T, which are located on either side of the
access barrier 14. The tracks T define the travel of the access
barrier 14 when moving upwardly from the closed to the open
position, and downwardly from the open to the closed position. The
barrier operator 12, may be controlled by wired or wireless
transmitter devices, which provide user-functions associated
therewith.
[0023] Continuing with FIG. 1, the barrier operator 12 mechanically
interrelates with the access barrier 14 through a counterbalance
system generally designated by the numeral 40. The counterbalance
system 40, depicted herein is advantageously in accordance with
pending U.S. patent application Ser. No. 11/165,138, which is
assigned to the Assignee of the present invention and incorporated
herein by reference. Generally, the counterbalance system 40
includes an elongated circular or non-circular drive tube 42 that
extends between tensioning assemblies 44 positioned proximate each
of the flag angles 28. Cable drum mechanisms 46 are positioned on
the drive tube 42 proximate ends thereof, which rotate with the
drive tube 42. The cable drum mechanisms 46 have a cable received
thereabout, which is affixed to the access barrier 14 preferably
proximate the bottom, such that rotation of the cable drum
mechanisms 46 operate to open or close the door 14 in conventional
fashion. A disconnect cable 48 is detachable mounted to either one
of the jambs 22,24. In particular, the disconnect cable 48 has one
end associated or coupled to the operator system and an opposite
end terminated by a cable handle 50. A handle holder 52 is secured
to either of the jambs 22,24 to hold the cable handle 50. The
handle holder 52 provides at least two different positions for the
cable handle so as to allow for actuation of the disconnect cable
48. The movement of the disconnect cable 48 connects and
disconnects the barrier operator 12 to the counterbalance system 40
as disclosed in the '138 application.
[0024] The barrier operator 12 is mounted to the header 26, and is
provided to move the access barrier 14 via the counterbalance
system 40 between open and closed positions. Because the barrier
operator 12 is in accordance with the barrier operator discussed in
pending U.S. patent application Ser. No. 11/165,138, the mechanical
features of the barrier operator 12 will not be discussed in great
detail herein. However, the components of the resynchronization
system 10 according to the concepts of the present invention that
are used to achieve the desired operation are as discussed
below.
[0025] FIG. 2 shows an encoder wheel 53 axially positioned and
attached to the drive tube 42. The encoder wheel 53 may be attached
to the drive tube 42 by an encoder sleeve 54 that is configured to
match the rotation of the drive tube 42. However, it is also
contemplated that the encoder wheel 53 may be attached in any
number of manners, and the ones discussed above should not be
construed as limiting. In any event, the encoder wheel 53 comprises
a plurality of evenly spaced slots 55, for example the encoder
wheel 53 may use 64 slots. The encoder wheel 53 rotates as the
drive tube 42 is rotated by a motor drive 56 and associated gearing
of the barrier operator 12. As the encoder wheel 53 rotates, the
slots 55 create a sequence of pulses that are detected by various
counting encoders, which will be discussed later. As will become
apparent, the encoder wheel 53 allows the re-synchronization system
10 to monitor the position and speed of the access barrier 14.
[0026] A blocker tab 57 is also provided by the counterbalance
system 40. As shown in FIG. 2, the blocker tab 57 extends radially
from a gear case cover 58, that along with the motor drive 56 are
configured to pivot or rotate as discussed in U.S. patent
application Ser. No. 11/165,138. The blocker tab 57 is configured
to be used in conjunction with a motor pivot encoder, which will be
elaborated on below. During operation of the barrier operator 12,
the motor drive 56 rotates a shaft gear 59 which engages other gear
assemblies (as discussed in U.S. patent application Ser. No.
11/165,138), which in turn rotate the encoder sleeve 54 as the
access barrier 14 is moved between limit positions. In any event,
the position of the blocker tab 57 relative to the motor pivot
encoder changes when the access barrier 14 reaches various
positions, such as an open or closed position; has contacted an
obstruction, and is in an intermediate position between open and
close; or when the disconnect cable 48 disconnects the operator 12
from the counterbalance system 40.
[0027] Continuing to FIG. 3, the barrier operator 12 comprises a
controller 60, which maintains the necessary application specific
or general purpose hardware, software, and memory for enabling the
concepts of the re-synchronization system 10. The controller 60
receives user and sensor input for evaluation, and generates
command signals so as to implement the operational features of the
barrier operator 12. The controller 60 may comprise a transceiver
62 to allow the controller 60 to receive communication signals
from, or to send communication signals to, one or more remote
devices that may include a portable wireless transmitter 64, a
wireless wall station 66, or a wireless home network 68 along with
other devices, appliances, or peripherals coupled thereto.
Typically, the portable transmitter 64 may have one or more primary
functions that can be invoked at the barrier operator 12, such as
an open/close function to actuate the access barrier 14 for
example. Additionally, the portable transmitter 64 may have one or
more secondary functions that may be invoked to control adjacent or
less used access barriers, or lighting fixtures, such as a light 70
for example. The wall station 66, which may be wireless, or
directly coupled to the controller 60 by a wire, may also include
the same primary or secondary functions discussed with respect to
the portable transmitter 64. However, it is also contemplated that
the wall station 66 may provide other functions, including but not
limited to auto-close, delay-open, delay-close, setting of a pet
height for the access barrier, learning other transmitters to the
barrier operator 12, and installation procedures used in learning
an access barrier to the barrier operator 12.
[0028] The controller 60 also includes a program button 72 that
places the controller 60 into a learn mode, and allows the
controller 60 to be learned to various portable transmitters 64,
and wireless wall stations 66. By providing the learn mode, it is
ensured that operation of the barrier operator 12 is restricted to
only those various transmitters/wall stations 64,66 that have been
properly learned to the controller 60. A program light 74 is also
provided by the controller 60 to give feedback to the user to
denote the status of the learn mode, the status of the controller
60, or status of any of the components associated with the
controller 60.
[0029] A memory unit 80 is also coupled to the controller 60. The
memory unit 80 may be external to the controller 60 as shown in
FIG. 3, or the memory unit 80 may be embedded (i.e. embedded
memory) within the logic circuitry of the controller 60. In any
case, the memory unit 80 may be comprised of either volatile or
non-volatile memory, including but not limited to EPROM
(electrically programmable read-only memory), EEPROM (electrically
erasable programmable read-only memory), Flash, DRAM (dynamic
random access memory), SRAM (static random access memory) or the
like. Stored in the memory unit 80 are a primary and a secondary
counter 82,84 that are capable of being incremented, decremented,
and reset to a desired value. The counters 82,84 may comprise
particular memory locations that are accessed by the controller 60,
such that the values stored therein can be incremented,
decremented, or otherwise altered in accordance with the concepts
of the present invention. Additionally, a timer 86 may also be
coupled to the controller 60. It should be appreciated that the
timer 86 may be a separate unit from that of the controller 60, or
embedded with the logic circuitry of the controller 60 itself. The
timer 86 is utilized by the controller 60 to monitor, measure, and
associate the occurrence of various events with a given time
duration, which will be discussed more fully below. In addition,
the motor drive 56 is coupled to the controller 60, and provides
the mechanical drive power to move the access barrier 14 between
opened and closed positions via the counterbalance system 40. A
current sensor 88 is coupled between the motor drive 56 and the
controller 60. The current sensor 88 allows the controller 60 to
monitor the current being drawn by the motor drive 56, such that
various changes in the operation of the barrier operator 12 may be
detected. For example, a fluctuation in motor current detected by
the current sensor 88 may cause the barrier operator 12 to timeout,
or otherwise stop functioning if an obstacle prevents the access
barrier 12 from closing completely.
[0030] Also coupled to the controller 60 is a counting encoder 90
and a motor pivot encoder 92 that is schematically shown in FIG. 3,
and physically shown in FIGS. 4-4A. The counting encoder 90
comprises a counting emitter 94 and a counting receiver 96 that are
spaced apart to allow the encoder wheel 53 to rotate therebetween.
Specifically, the counting emitter 94 emits a suitable light beam,
such as an infrared or laser beam, that is received by the counting
receiver 96. However, as the encoder wheel 53 rotates, the slots 55
interrupt the continuous light beam emitted by the counting emitter
94 to generate light pulses. Thus, as the encoder wheel 53 rotates,
the counting receiver 96 detects the light pulses, which are
counted and processed by the controller 60 to resolve the relative
location of the access barrier 14 down to about 0.1 inch.
Therefore, the controller 60, by analyzing the number of pulses
detected over a given time period as established by the timer 86,
is able to ascertain the rotational speed of the encoder wheel 53
and, as such, the speed of the barrier.
[0031] Since the spacing between the slots 55 is uniform about the
encoder wheel 53, the software maintained by the controller 60
cannot resolve the relationship of each pulse to the location of
the drive tube 42. Therefore, if the barrier operator 12 is
disconnected from the access barrier 14 and moved, the distance
traveled by the access barrier 14 can be determined, but the
direction of travel cannot. To overcome this deficiency, the
encoder wheel 53 may incorporate a directional marker 98, which
allows the controller 60 to determine the travel direction of the
drive tube 42 relative to the linear position of the access barrier
14. The directional marker 98 may be in the form of a blocked slot.
In other words, in a position where a slot would normally be
encountered, the marker is detected by the encoder 90. In essence,
the marker 98 is a filled-in slot. Alternatively, the directional
marker 98 may be larger or of a different size than the slots 55,
and may be interspersed among the slots 55 of the encoder wheel 53
in a symmetrical or uniform arrangement. For example, one
directional marker 98 may appear after every ten slots 55. To
ascertain the relative movement of the directional marker 98, the
counting emitter 94 and the counting receiver 96 are utilized in a
manner similar to that discussed above with regard to measuring the
speed of the access barrier 12. Specifically, the directional
marker 98 is identified by a pulse that is of a longer or different
duration than that generated by the slots 55. Once the directional
marker 98 has been detected, the controller 60 receives a
directional pulse from the counting encoder 90 and associates the
rotational direction of the encoder wheel 53 with a particular
linear movement of the access barrier 14. In other words, using the
directional marker 98 to create light pulses of a longer or
different duration, allows the software executed by the controller
60 to determine the location and movement direction of the access
barrier 14. In addition, the counting encoder 90 allows the
controller 60 to record the pulse signals that are generated for
both the speed and direction of the access barrier 14, as the
access barrier 14 is manually moved by a user or automatically
moved by the barrier operator 12. Although any barrier movement
distance can be associated with a light pulse, the present
embodiment utilizes a distance of 0.1 inch for each light pulse
detected. For example, if the access barrier 14 is disconnected
from the barrier operator 12, and the access barrier 14 is manually
moved up, the software component of the controller 60 along with
the counting encoder 90 may continue to count pulses and locate the
directional pulse. For example, when the access barrier 14 is
stopped with the pulse counter at a count of 278 pulses, for
example, the directional pulse is located at the 270th pulse
location. If the access barrier 14 system is manually moved again
later, the software component of the controller 60 will expect the
directional pulse to appear again eight pulses later given that the
access barrier 14 is being pulled downward, or to appear again 56
pulses later if the access barrier 14 is being moved in the upward
direction.
[0032] Although use of a marker/detector system, such as the
slotted encoder wheel 53 and light beam of the counting encoder 90
is disclosed, it will be appreciated that other types of markers
could be used. For example, equally spaced magnets of equal field
strength could be used in a manner equivalent to the slots 55
wherein a magnet with increased or decreased field strength
distinguishable from the other magnets could be used as the
directional marker 98. As such, an appropriate Hall-effect sensor
or other sensor could be used to detect the passing of the
magnets.
[0033] In another embodiment, shown in FIG. 5, the encoder wheel 53
may be mounted to the shaft 59 of the motor drive 56. To measure
the speed and direction of rotation of the shaft 59, the counting
encoder 90 is suitably mounted about the encoder wheel 53 so as to
generate a series of pulses as the shaft 59 rotates the encoder
wheel 53 which utilizes an appropriate directional marker.
[0034] The motor pivot encoder 92 comprises a compliance emitter
100 and a compliance receiver 102, which detects the presence or
absence of the blocker tab 57 that is configured to rotate between
the compliance emitter 100 and the compliance receiver 102.
Specifically, the blocker tab 57 radially or otherwise extends from
the gear case cover 58 that is rotatably mounted to a gear case
housing 110 that supports the motor drive 56. The compliance
emitter 100 is configured to emit a suitable light beam, such as an
infrared or laser beam, to be received by the compliance receiver
102. As the access barrier 14 moves into a fully open or fully
closed position, or if the access barrier 14 encounters an
obstacle, or if the operator is disconnected from the barrier, the
mechanical power supplied by the motor drive 56 to drive the drive
tube 42, and the associated counterbalance system 40, causes the
motor drive 56 and the attached gear case cover 58 to at least
partially rotate, as shown in FIGS. 6A-C. As the gear case cover 58
rotates, the blocker tab 57 also rotates between the compliance
emitter 100 and the compliance receiver 102.
[0035] Generally, when the access barrier 14 is fully opened or
fully closed the blocker tab 57 does not block the beam emitted by
the compliance emitter 100. However, if an obstruction force that
exceeds a predetermined amount is imparted to the access barrier 14
as it travels downward, a biasing force is overcome and the motor
drive 56 and the other associated supporting assemblies, including
the gear case cover 58 rotate, as shown in FIG. 6A. When this
occurs, the rotation of the gear case cover 58 causes the blocker
tab 57 to interfere with the light beam generated by the compliance
emitter 100. The controller 60, which continuously monitors the
motor pivot encoder 92, then generates the appropriate signals to
stop the operation of the motor drive 56, so as to prevent the
access barrier 14 from moving further.
[0036] In the case where the access barrier 14 is moving into a
fully closed position, as shown in FIG. 6B, the blocker tab 57
changes from an obstruction indicator to a motor pivot position,
and speed indicator. Briefly, during the closing movement of the
access barrier 14, the motor drive 56, begins to pivot downward,
causing the gear case cover 58 to rotate. The rotation of the gear
case cover 58 results in the leading edge of the blocker tab 57
moving so as to interfere with the light emitted from the
compliance emitter 100. As the access barrier 14 continues to move
into a fully closed position, the trailing edge of the blocker tab
57 moves past the compliance emitter 100, re-establishing the
transmission of light between the compliance emitter 100 and the
compliance receiver 102, and indicating to the controller 60 that
the access barrier 12 is in a fully closed or locked position.
Thus, the detection of the leading and trailing edges of the
blocker tab 57 results in the controller 60 determining that the
access barrier 14 is in a fully closed position.
[0037] When the access barrier 14 is actuated from an initially
closed position, the motor drive 56 rotates or pivots upwardly and
causes the blocker tab 57 to move through the motor pivot encoder
92 in a manner opposite to that discussed with respect to the
access barrier 14 being closed. As such, after the leading and
trailing edge of the blocker tab 57 has been detected by the motor
pivot encoder 92, the controller 60 determines that the access
barrier 14 is moving toward the fully opened or operation position,
as shown in FIG. 6C.
[0038] It should also be appreciated that in one embodiment the
presence or absence of the blocker tab 57 may be used to denote
that the access barrier 14 is in a fully opened or fully closed
position. For example, in one embodiment of the re-synchronization
system 10, the blocker tab 57 may be configured so that its leading
and trailing edges are not used to determine whether the access
barrier 14 is fully open or closed. Rather, the detection or
non-detection of the blocker tab 57 by the motor pivot encoder 92
may be used by the controller 60 to determine whether the access
barrier 14 is in either a fully opened or fully closed position.
For example, the re-synchronization system 10 may be configured to
identify that the access barrier 14 is in a fully closed position
if the blocker tab 57 is detected by the motor pivot encoder 92
prior to the initial movement of the access barrier 14 from the
closed limit position toward the open limit position. Such
detection by the motor pivot encoder is sent to the controller
which then resets at least the primary count and, if desired, the
secondary count. Alternatively, the access barrier 14 may be
identified as being in a fully opened position if the blocker tab
57 is not detected by the motor pivot encoder 92 prior to an
initial movement of the access barrier 14. It is also evident to
one skilled in the art that the detection or non-detection of the
blocker tab 57 may be used to signify a fully opened or fully
closed access barrier 14, or vice versa.
[0039] The primary and secondary counters 82,84 along with the
current sensor 88, the counting encoder 90, and the motor pivot
encoder 92 form the primary components of the re-synchronization
system 10. As discussed previously, the primary and secondary
counters 82,84 may comprise various memory locations of the memory
80. Furthermore, the term count as used herein, refers to the
numerical representation of the various distances moved (i.e.
travel), when the access barrier 14 has been manually moved by an
individual or when the access barrier 14 has been moved by the
barrier operator 12. As such, the following discussion will be
directed to the interrelationship between the various components of
the re-synchronization system 10 as well as the steps taken by the
re-synchronization system 10 when in operation.
[0040] During normal operation of the resynchronization system 10,
when the access barrier 14 is in a fully open or fully closed
position, the primary and secondary counters 82,84 initially
contain equal count values. As used herein, the phrase "operator
move" refers to the movement of the access barrier 14 that is
initiated by the barrier operator 12. The phrase "manual move" as
used herein, refers to any repositioning of the access barrier 14
performed while the access barrier 14 is disengaged from the
counterbalance system 40. Thus, after a manual move, the primary
counter 82 contains a "measured distance" count value that is equal
to the distance measured by the encoder wheel 53 for the prior
operator move less the amount of travel completed by any manual
repositioning of the access barrier 14 that occurs prior to any
subsequent operator move. Should a subsequent operator move be
initiated, the measured distance count is decremented (or
incremented) in accordance with the amount of travel of the access
barrier 14 as it moves upward or downward. The secondary counter 84
prior to any operator move contains a count value, referred to
hereinafter as a "travel distance" count value, which is equal to
the full travel distance between the closed and opened positions
(i.e. distance between the bottom of the access barrier and floor,
when the access barrier 14 is fully opened) established by a
barrier operator profiling operation that is completed when the
barrier operator 12 was installed, and put into service. The
details of such profiling operation are set forth in detail in U.S.
patent application Ser. No. 11/165,138. The secondary counter 84,
in the case of a manual move, is not updated, and is otherwise
unaware of any manual movement of the access barrier 14. The
interaction between the primary and secondary counters 82,84 and
the effect of a manual movement of the access barrier 14 will be
fully set forth in the operational steps set forth below.
[0041] The operational steps taken by the re-synchronization system
10 are generally designated by the numeral 200 as shown in FIG. 7
of the drawings. The following discussion is based on the initial
conditions, wherein the operational limits of the access barrier 14
have been profiled by the barrier operator 12 prior to use, and the
access barrier 14 has been identified as having seven feet (about
213 centimeters) of travel between its open and closed positions
(i.e. the travel distance being measured between the bottom of the
access barrier 14 and the floor, when the access barrier 14 is in a
fully opened position). This profiled travel distance is stored in
a profile table 205 of the memory 80, and utilized by the secondary
counter 84 as the "travel distance" count value that is decremented
during an operator move. The primary counter 82 contains the
"measured distance" count value as previously discussed. Following
an operator move, the decremented primary counter 82 is reset to
the "measured distance" count that was measured by the counting
encoder 90 during the previous completed operator move. Thus, the
primary counter 82 is reset with an updated "measured distance"
count value after each successive completed operator move. In
addition, the secondary counter 84, which is decremented only
during an operator move, is reset to the travel distance count
after each completed operator move.
[0042] Continuing with the operational steps of the process 200,
the access barrier 14 is initially in a fully closed position, the
primary counter 82 and secondary counter 84 are both equal to the
travel distance count, which for the purpose of this example is
seven feet as discussed. As previously discussed, the detection or
lack of detection of the blocker tab 57 by the motor pivot encoder
92 may be used by the controller 60 as an indicator of the initial
position of the access barrier 14. Thus, the commencement of any
operator move of the access barrier 14 causes the count values
contained in both the primary and secondary counters 82,84 to be
decremented in accordance with the amount of travel of the access
barrier 14 completed by such operator move.
[0043] At step 210, the access barrier 14, is moved into a fully
opened position by an operator move, and then subsequently manually
moved, such that the bottom of the access barrier 14 is four feet
(about 121.9 centimeters) above the ground. Because the access
barrier 14 was manually moved to a position four feet above the
ground, the counting encoder 90 decrements the primary counter 82
so that it has a current "measured distance" count value of four
feet, while the secondary counter 84 continues to have a "travel
distance" count value equal to the travel distance of seven feet On
the next operator move of the barrier operator 12, the access
barrier 14 is driven downward into its closed position, and it is
this downward movement that serves as the basis for the following
discussion.
[0044] Once the access barrier 14 begins to be driven downward by
the barrier operator 12 during the operator move, the controller 60
waits for a pulse to be generated from the encoder wheel 53, as
indicated at step 220. If a pulse is not produced by the encoder
wheel 53, the process 200 continues at step 220 until one is
generated and received by the controller 60. However, if a pulse is
produced by the encoder wheel 53 and detected by the controller 60,
the process 200 continues to step 230, where the primary counter 82
is decremented by 0.10 inches (about 0.254 centimeters), although
other decrement values may be utilized. Somewhat simultaneously
with step 230, step 240 is preformed wherein the profile data for
the current count value contained in the primary counter 82 is
obtained from the profile table 205 of the memory 80.
[0045] The profile table 205 contains various operating data
relating to the operation of the barrier operator 12 and access
barrier 14, which is gathered during the profiling step performed
during the installation of the access barrier 14 and the barrier
operator 12. For example, the profile table 205 may contain data
corresponding to specific positions of the access barrier 14
throughout discrete positions of its travel distance. For example,
motor current, pulse velocity, barrier speed, motor torque and any
other operational parameters may be stored in the profile table for
each travel increment of the access barrier 14. After the profile
data has been acquired from the profile table 205, it is compared
with the sampled motor current, pulse velocity values and the like
that have been acquired in real-time by the counting encoder 90,
the current sensor 88, and any other sensor linked to the
controller, as indicated at step 250. At step 250, the process 200
determines whether there is a match between the profile data and
the sampled data. If a match is established, then the process 200
returns to step 220.
[0046] Somewhat simultaneously with steps 240 and 250, the process
200 continues to step 260 where the controller 60 determines
whether the primary counter 82 has been decremented to a zero
value. If the primary counter 82 has been decremented to zero, the
process 200 continues to step 270, where the controller 60
determines whether the blocker tab 57 has been detected by the
motor pivot encoder 92. Next, if the blocker tab 57 has not been
detected, the count value currently stored in the primary counter
82 is changed to the count value stored in the secondary counter
84, thus causing the profile of the access barrier 14 to be
realigned as indicated at steps 280, and 290. However, if at step
270, the blocker tab 57 is not detected by the controller 60, the
process 200 exits, as indicated at step 272, as the access barrier
14 has been moved down to a fully closed position. However, if the
primary counter 82 does not equal zero at step 260, the process 200
moves to step 300. At step 300, the secondary counter 84 is
decremented by 0.10 inches, but should not be construed as limiting
as any increment value may be used. After the secondary counter 84
has been decremented, the secondary counter 84 is analyzed by the
controller 60 to determine if it is equal to zero, as indicated at
step 310. If the secondary counter 84 is equal to zero, then the
process 200 exits as indicated at step 272. However, if the
secondary counter 84 does not equal zero, then the process 200
continues to step 320, where the controller 60 acquires the profile
data, from the profile table 205 that corresponds to the current
position of the access barrier 14 that is stored as the current
count value in the secondary counter 84.
[0047] Once the profiles for the current counts of the primary and
secondary counters 82,84 have been acquired, the values are
compared to the sampled, real-time values of motor current, and
pulse velocity, as indicated at step 250. If the profiled data
relating to the current count in the primary counter matches the
real-time data (motor current, pulse velocity, etc. for example)
acquired by the controller 60, the process 200 by way of step 330,
continues to step 220 as previously discussed, whereby the
operational steps 220-330 are repeated. However, if the profiled
data (motor current, pulse velocity, etc.) from the profile table
205 relating to the current count of the secondary counter 84
matches or more closely approximates the sampled, real-time data,
then the process 200 by way of step 340, continues to step 280. At
step 280 the current count value of the primary counter 82 is
changed to the current count value stored in the secondary counter
84, resulting in the realignment of the primary counter 82, as
indicated at step 290. However, if at step 340, the controller 60
determines that the profiled motor current and velocity values
corresponding to the current count value of the access barrier 14
that is stored in the secondary counter 84 does not match the
sampled data, then the process 200 continues to step 350, whereby
the barrier operator 12 reverses the direction in which the access
barrier 14 is being moved.
[0048] It will, therefore, be appreciated that one advantage of one
or more embodiments of the present invention is that a
re-synchronization system is able to determine the correct amount
of movement needed to close or open an access barrier. Still
another advantage of the present invention is that the
re-synchronization system is able to monitor and compare real-time
speed, direction, and motor current values for the access barrier
with values that have been profiled prior to the access barrier
being put into use. An additional advantage of the present
invention is that the re-synchronization system is compatible with
pivoting barrier operators.
[0049] Although the present invention has been described in
considerable detail with reference to certain embodiments, other
embodiments are possible. Therefore, the spirit and scope of the
appended claims should not be limited to the description of the
embodiments contained herein.
* * * * *